Process for reacting aromatic compounds

ABSTRACT

A process for reacting an aromatic compound, hydrogen and at least one of carbon monoxide and an alcohol containing from 1 to 6 carbon atoms in the presence of a cadmium-containing catalyst is disclosed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to the reaction between an aromaticcompound, hydrogen and at least one of carbon monoxide and an alcoholcontaining from 1 to 6 carbon atoms, and more particularly concerns suchreaction in the presence of a cadmium-containing catalyst.

2. Description of the Prior Art

The production from less valuable materials of aliphatic compoundsboiling in the gasoline range, of aromatic compounds, and ofintermediates useful for the production of such aliphatic and aromaticcompounds, is highly desirable and has been the object of several priorart methods involving the use of cadmium-containing catalysts. Forexample, Woodruff et al., U.S. Pat. Nos. 1,625,924 and 1,625,928,disclose a method for producing methanol by reacting oxides of carbonwith hydrogen at high pressures and in the presence of a catalystcomprising one or more non-reducible metal oxides, such as zinc,magnesium, cadmium, chromium, vanadium, or tungsten, and one or moreeasily reducible metal oxides, such as copper, silver, iron, nickel, orcobalt, and a metallic halide. Melaven et al., U.S. Pat. No. 2,301,735,disclose a process for converting heavy hydrocarbon oils into gasolineby contacting the heavy oils with a catalyst comprising silicaimpregnated with a cadmium compound.

Klotz, U.S. Pat. No. 4,269,813, discloses a crystalline borosilicatecatalyst comprising a molecular sieve material having the followingcomposition in terms of mole ratios of oxides:

    0.9±0.2M.sub.2/n O:B.sub.2 O.sub.3 :ySiO.sub.2 :zH.sub.2 O

wherein M is at least one cation, n is the valence of the cation, y is avalue within the range of 4 to about 600, and z is a value within therange of 0 to about 160, and providing a specific X-ray defractionpattern. M represents an alkali metal cation, an alkaline earth metalcation, an ammonium cation, an alkylammonium cation, a hydrogen cation,a catalytically active metal cation, or mixtures thereof. Klotz alsodiscloses that the original cation "M" in the above formulation can bereplaced by tetraalkylammonium cations, metal ions, ammonium ions,hydrogen ions, and mixtures thereof, particularly hydrogen, rare earthmetals, aluminum, metals of Groups IB, IIB and VIII of the PeriodicTable, noble metals, manganese, and other catalytically-active materialsand metals known to the art. The catalytically-active components can bepresent at concentrations from about 0.05 to about 25 weight percent ofthe crystalline borosilicate. Klotz discloses that the crystallineborosilicate can be employed effectively as a catalyst for variousprocesses including reforming, hydrocracking, transalkylation,disproportionation, isomerization, and alkylation, and is particularlysuitable for the isomerization of xylenes, the conversion ofethylbenzene and the conversion of alcohols, such as methanol, to usefulproducts, such as aromatics or olefins.

Fraenkel et al., U.S. Pat. No. 4,294,725, disclose a Fischer-Tropschcatalyst comprising a particulate synthetic zeolite incorporating atransition metal reduced in situ by a preselected vaporous reductantmetal and a method of making the catalyst. In the disclosed method formaking the catalyst, at least one reducible transition metal isincorporated by ion exchange into a particulate synthetic zeolitecatalyst support having ion-exchange properties, and the transitionmetal is then reduced with a vapor of at least one reductant metalhaving a reduction potential greater than the reduction potential of thetransition metal. In one specific embodiment disclosed, cadmium isdisclosed as a reducing metal which is present along with a transitionmetal in the final catalyst produced. Depending upon the conditionsemployed, saturated and unsaturated hydrocarbon products containing fromone to five carbon atoms and an unidentified oxygenated product wereproduced when a catalyst containing cobalt as the transition metal andcadmium as the reducing metal was employed.

Chu, U.S. Pat. No. 4,384,155, discloses a process for the conversion ofaromatic compounds, either alone or in admixture with a suitablealkylating agent, such as methanol or ethylene, to dialkylbenzenecompounds which are rich in the 1,4-dialkylbenzene isomer, in thepresence of a particular type of zeolite catalyst having asilica-to-alumina mole ratio of at least 12 and a constraint index ofabout 1-12, and containing a minor proportion of cadmium depositedthereon.

In addition, cadmium-containing catalysts have been employed in otherunrelated methods. For example, Wietzel et al., U.S. Pat. No. 1,562,480,disclose a method for synthesizing higher molecular weight organiccompounds containing oxygen by reacting an aliphatic alcohol with carbonmonoxide and optionally with hydrogen at a temperature of at least about400° C. and in the presence of the catalyst comprising bothhydrogenating and hydrating constituents. Suitable hydrogenatingconstituents are disclosed as including copper, silver, gold, tin, lead,antimony, bismuth, zinc, cadmium and thallium, and suitable hydratingconstituents are disclosed as including titanium, zirconium, thorium,vanadium, niobium, manganese, cerium, lanthanum, tantalum, chromium,molybdenum, tungsten, uranium, didymium, glucinium and aluminum.

Perkins et al., U.S. Pat. No. 2,107,710, disclose a method forhydrolyzing a halohydrocarbon in the vapor phase and in the presence ofa catalyst comprising silica gell impregnated with one or more salts ofmetals belonging to the Groups IIB, IIIB, IVA or B, or VB of theperiodic system, for example, beryllium nitrate, magnesium sulfate, zincsulfate, cadmium nitrate, boron fluoride, aluminum chloride, stannouschloride, lead nitrate, titanium tetrachloride, antimony nitrate orbismuth chloride.

La Lande, U.S. Pat. No. 2,395,931, discloses a decolorizing adsorbent orcatalyst comprising a water-insoluble metal aluminate formed by thereaction in aqueous solution of an alkali metal aluminate and awater-soluble salt of a metal capable of forming a water-insoluble metalaluminate in the presence of a compound yielding ammonium ions. Suitablewater-soluble salts of metals capable of forming a water-insoluble metalaluminate include the chlorides or sulfates of magnesium, calcium, oraluminum, and soluble salts of strontium, barium, lead, copper, cadmium,iron, chromium, cobalt, nickel, manganese, thorium, cerium, beryllium,molybdenum, tin, titanium, zirconium, tungsten and vanadium. Thecatalyst is disclosed for use in decolorizing hydrocarbon oils.

Mecorney et al., U.S. Pat. No. 2,697,730, disclose a catalyst comprisingone or more metals, such as copper, silver, chromium, manganese, nickel,tungsten, cobalt, iron, cadmium, uranium, thorium, tin or zinc, eitherin the form of the elemental metals, their oxides, hydroxides, or salts,wherein the metal component is supported on activated alumina ordiatomaceous earth. The catalyst is disclosed for use in synthesizinghigher ketones.

Cislak et al., U.S. Pat. No. 2,744,904, disclose a process for preparingpyridine and 3-picoline by reacting acetylene, ammonia and methanol inthe presence of a catalyst comprising activated alumina impregnated withcadmium fluoride.

Finch et al., U.S. Pat. No. 2,763,696, disclose a method for reducingalpha- or beta-olefinic aldehydes or ketones to the corresponding alpha-or beta-unsaturated alcohols by direct hydrogenation of the aldehydes orketones in the vapor phase and in the presence of a catalyst comprisingelemental cadmium, its oxide, or a mixture thereof, and one or moreadditional metals known to have hydrogenating-dehydrogenatingcharacteristics, such as a heavy metal selected from the first, second,sixth or eighth groups of the Periodic Table of the Elements. Thesemetal components of the catalyst are disclosed as being employed eitherin the unsupported state or as supported on a suitable carrier, such assilica, alumina, kieselguhr or other diatomaceous earth material, pumiceor the like.

Pearson et al., U.S. Pat. No. 3,725,531, disclose a process whereinindustrial off-gases containing organic sulfur components are contactedwith an alumina base catalyst to convert these organic sulfur componentsto easily removable compounds, such as carbon dioxide and elementalsulfur. The catalyst employed comprises an alumina base support incombination with at least one metal selected from strontium, calcium,magnesium, zinc, cadmium, barium and molybdenum.

Eurlings et al., U.S. Pat. No. 3,862,055, disclose a method for thepreparation of a catalyst system having a catalytically-active componentof an oxide, metal or alloy of any one or more of copper, zinc, cadmium,nickel, cobalt, iron, manganese or magnesium, homogeneously dispersedover a solid particulate inorganic thermostable carrier material.Suitable inorganic thermostable materials, for use as the carrier, aredisclosed generally as including synthetic or mineral carrier materials,such as alumina or silica.

Eberly, U.S. Pat. No. 4,358,297, discloses a process wherein aparticulate sorbent mass of zeolite, which has been ion-exchanged withzinc or cadmium to provide pore size openings of at least about 5angstroms, is contacted with a moist hydrocarbon process stream whichcontains sulfur, sulfur compounds, and other contaminants, these beingadsorbed onto the particulate sorbent mass.

Mathe et al., U.S. Pat. No. 4,361,500, disclose a process for thepreparation of a supported metal catalyst containing at least one metalbelonging to Group A and optionally at least one metal belonging toGroup B, wherein Group A encompasses palladium, rhodium, ruthenium,platinum, iridium, osmium, silver, gold and cadmium, and Group Bencompasses zinc, mercury, germanium, tin, antimony and lead. Thispatent discloses that any of the known substances commonly used assupports for catalysts can be used as a support in the catalystdisclosed, and the following supports are specifically mentioned:activated carbons, aluminum oxides, silicon dioxides, aluminosilicatesand various molecular sieves, and barium sulfate. The catalyst isdisclosed for use in hydrogenation reactions.

OBJECTS OF THE INVENTION

It is a general object of the present invention to provide a method forthe direct production of more valuable aromatic compounds from lessvaluable aromatic compounds.

More particularly, it is an object of the present invention to provide asingle-step method for the direct production of alkylated aromaticcompounds.

It is a further object of the present invention to provide a single-stepmethod for the direct and highly selective production of p-xylene andpseudocumene.

It is a related object of the present invention to provide a single-stepmethod for the direct production of more valuable aromatic compoundsfrom less valuable aromatic compounds employing a catalyst havingimproved activity maintenance.

Other objects and advantages of the invention will become apparent uponreading the following detailed description and appended claims.

SUMMARY OF THE INVENTION

The present invention is a method for reacting an aromatic compound,hydrogen and at least one of carbon monoxide and an alcohol containingfrom 1 to 6 carbon atoms, at a temperature in the range of from about300° C. to about 480° C., at a pressure in the range of from about 5 toabout 150 kilograms per square centimeter, and in the presence of acatalyst composition comprising a cadmium component and a supportmaterial having acidic properties. The cadmium component is in the formof the elemental metal, its oxide or salt or a combination thereof, andis present at a concentration level in the range of from about 0.1 toabout 20 weight percent, calculated as cadmium oxide and based on theweight of the catalyst.

DETAILED DESCRIPTION

Catalysts suitable for use in the method of this invention comprise acadmium component and a support material having acidic properties. Thecadmium component can be present either as a component deposited on thesupport or as a component formed from cadmium ions exchanged into thesupport replacing exchangeable cations in the support. The cadmiumcomponent is in the form of elemental cadmium, its oxide or salt or acombination thereof, and is present at a concentration level in therange of from about 0.1 to about 20 weight percent, calculated ascadmium oxide and based on the weight of the catalyst. Preferably thecadmium component is present at a concentration level of from about 1 toabout 10 weight percent, calculated as cadmium oxide and based on theweight of the catalyst. The cadmium component is preferably in the formof cadmium oxide.

Preferably the catalyst additionally comprises a thorium component. Thethorium component has essentially no catalytic activity itself in themethod of this invention, but serves to promote the catalytic activityof the cadmium component. Like the cadmium component, the thoriumcomponent can be present either as a component deposited on the supportor as a component of the support formed from thorium ions exchanged intothe support replacing exchangeable cations in the support. In addition,a thorium component can be a component of the support formed byadmixture of a thorium component with an amorphous refractory inorganicoxide, such as alumina, silica or silica-alumina. The thorium componentis in the form of elemental thorium, its oxide or salt or a combinationthereof, and is present at a concentration level in the range of fromabout 1 to about 25 weight percent, calculated as thorium oxide andbased on the weight of the catalyst. Preferably, the thorium componentis present at a concentration level of from about 3 to about 15 weightpercent, calculated as thorium oxide and based on the weight of thecatalyst. The thorium component is preferably in the form of thoriumoxide.

Any porous support material having acidic properties is suitable for usein the catalyst employed in the method of this invention. Thus, suitablesupports comprise an amorphous refractory inorganic oxide, a molecularsieve, a pillared smectite or vermiculite clay, or a combinationthereof. Refractory inorganic oxides having acidic properties typicallycomprise alumina, zirconia, titania, an oxide of a metal of thelanthanide series, an oxide of a metal of the actinide series, acombination thereof, or a combination thereof with silica or magnesia.The amorphous refractory inorganic oxide can also include adjuvants,such as one or more oxides of phosphorus or boron, or a halogen, such aschlorine or fluorine.

The support material of the catalyst employed in the method of thepresent invention can also comprise a crystalline molecular sievecontaining exchangeable cations and can be in the unexchanged orcation-exchanged form. A suitable molecular sieve comprises acrystalline aluminosilicate, crystalline borosilicate or a combinationthereof. A suitable crystalline aluminosilicate includes chabazite,clinoptilolite, erionite, mordenite, zeolite A, zeolite L, zeolite X,zeolite Y, ultrastable large-pore zeolite Y, zeolite omega, or aZSM-type zeolite such as ZSM-5, ZSM-11, ZSM-12, ZSM-35, ZSM-38 orZSM-48.

Mordenite-type crystalline aluminosilicates have been discussed in thepatent art, for example, in Kimberlin, U.S. Pat. No. 3,247,098; Benesiet al., U.S. Pat. No. 3,281,483; and Adams et al., in U.S. Pat. No.3,299,153. Those portions of each of these patents that are directed tomordenite-type aluminosilicates are specifically incorporated byreference herein. Synthetic mordenite-type crystalline aluminosilicates,designated as Zeolon, are available from the Norton Company ofWorcester, Mass.

One example of a crystalline molecular sieve that is suitable for use inthe support of the catalyst employed in method of the present inventionis an unexchanged high sodium content, Y-type zeolitic crystallinealuminosilicate, such as the sodium-Y molecular sieve, designated asCatalyst Base 30-200, and obtained from the Linde Division of UnionCarbide Corporation.

Another example of a crystalline molecular sieve that can be employed inthe support of the catalyst employed in the method of the presentinvention is a metal-exchanged, Y-type molecular sieve. Y-type, zeoliticmolecular sieves are discussed in U.S. Pat. No. 3,130,007. Themetal-exchanged, Y-type molecular sieve can be prepared by replacing theoriginal cation associated with the molecular sieve by a wide variety ofother cations according to techniques that are known in the art. Ionexchange techniques have been disclosed in many patents, several ofwhich are U.S. Pat. Nos. 3,140,249; 3,140,251; and 3,140,253.Specifically, a mixture of rare earth metals can be exchanged into aY-type zeolitic molecular sieve, and such rare earth metal-exchanged,Y-type molecular sieve can be employed suitably in a support used in thecatalyst employed in the method of the present invention. Specificexamples of suitable rare earth metals are cerium, lanthanum, andpraesodymium. In one particularly preferred embodiment, cadmium ions areexchanged into a Y-type zeolitic molecular sieve, with the result beingthat the cadmium component of the catalyst is a component of thecatalyst support.

Ultrastable, large-pore, Y-type, zeolitic crystalline aluminosilicatematerial is described in U.S. Pat. Nos. 3,293,192 and 3,449,070. Each ofthese patents is specifically incorporated by reference herein. Bylarge-pore material is meant, a material that has pores which aresufficiently large to permit the passage thereinto of benzene moleculesand larger molecules and the passage therefrom of reaction products.

The ultrastable, large-pore, Y-type, zeolitic crystallinealuminosilicate material that is preferred for use in the support of thecatalyst employed in the method of this invention exhibits a cubic unitcell dimension and hydroxyl infrared bands that distinguish it fromother aluminosilicate materials. The cubic unit cell dimension of thepreferred ultrastable, large-pore, crystalline aluminosilicate is withinthe range of about 24.20 angstroms to about 24.55 angstroms. Thehydroxyl infrared bands obtained with the preferred ultrastable,large-pore, crystalline aluminosilicate material are a band near 3,745cm⁻¹ (3,745±5 cm⁻¹), a band near 3,695 cm⁻¹ (3.690±10 cm⁻¹), and a bandnear 3,625 cm⁻¹ (3,610±15 cm⁻¹). The band near 3,745 cm⁻¹ may be foundon many of the hydrogen-form and de-cationized aluminosilicatematerials, but the band near 3,695 cm⁻¹ and the band near 3,625 cm⁻¹ arecharacteristic of the preferred ultrastable, large-pore, Y-type,zeolitic crystalline aluminosilicate material that is used in thecatalyst of the present invention. The ultrastable, large-pore, Y-type,zeolitic crystalline aluminosilicate material is also characterized byan alkaline metal content of less than 1%.

Other molecular sieve materials that are useful in the support of thecatalyst employed in the method of the present invention are ZSM-typecrystalline aluminosilicate molecular sieves. Suitable crystallinealuminosilicates of this type typically have silica-to-alumina moleratios of at least about 12:1 and pore diameters of at least 5angstroms. A specific example of a useful crystalline aluminosilicatezeolite of the ZSM-type is ZSM-5, which is described in detail in U.S.Pat. No. 3,702,886. Other crystalline aluminosilicate zeolites of theZSM-type contemplated according to the invention include, ZSM-11, whichis described in detail in U.S. Pat. No. 3,709,979; ZSM-12, which isdescribed in detail in U.S. Pat. No. 3,832,449; ZSM-35, which isdescribed in U.S. Pat. No. 4,016,245; and ZSM-38, which is described indetail in U.S. Pat. No. 4,046,859. All of the aforesaid patents areincorporated herein by reference. A preferred crystallinealuminosilicate zeolite of the ZSM-type is ZSM-5.

An additional molecular sieve that can be used in the catalyticcomposition of the present invention is a crystalline borosilicate,which is described in U.S. Pat. No. 4,269,813, which patent isspecifically incorporated herein by reference. A suitable crystallineborosilicate is a molecular sieve material having the followingcomposition in terms of mole ratios of oxides:

    0.9±0.2M.sub.2/n O:B.sub.2 O.sub.3 :ySiO.sub.2 :zH.sub.2 O

wherein M is at least one cation having a valence of n, y is within therange of 4 to about 600, and z is within the range of 0 to about 160,and providing an X-ray pattern providing the following X-ray diffractionlines and assigned strengths:

    ______________________________________    d Angstroms   Assigned Strength    ______________________________________    11.2 ± 0.2 W- VS    10.0 ± 0.2 W- MS    5.97 ± 0.07                  W- M    3.82 ± 0.05                  VS    3.70 ± 0.05                  MS    3.62 ± 0.05                  M- MS    2.97 ± 0.02                  W- M    1.99 ± 0.02                  VW- M    ______________________________________

M can be a cadmium ion, and thus the cadmium component can beincorporated into the crystalline borosilicate molecular sieve supportitself, in addition to or instead of being deposited on the surface ofthe crystalline borosilicate molecular sieve support.

Suitable methods for preparing the aforesaid crystalline borosilicatemolecular sieve are disclosed in Klotz, U.S. Pat. No. 4,269,813 and inHaddid, European Patent Application No. 82303246.1 which was publishedon Jan. 5, 1983.

Pillared smectite and vermiculite clays, which are also suitable for usein, or as, the support component of the catalyst employed in the methodof this invention, are often referred in the literature as pillaredinterlayered clays and occasionally as molecular sieves. The smectiteclays comprise montmorillonite, beidellite, montronite, volchonskoite,hectorite, saponite, stevensite, sauconite and pimelite. Some pillaredsmectite and vermiculite clay materials that are suitable for use in thesupport of the catalyst employed in the method of this invention, andmethods for preparing such clays, are disclosed in Vaughan et al., U.S.Pat. No. 4,176,090; Shabria et al., U.S. Pat. No. 4,216,188; Shabtai,U.S. Pat. No. 4,238,364; D'Aniello, U.S. Pat. No. 4,380,510; Pinnavaia,"Intercalated Clay Catalysts," Science, Vol. 220, pages 365-371 (Apr.22, 1983) and Vaughan et al., "Preparation of Molecular Sieves Based onPillared Interlayered Clays (PILC)," Fifth International Conference onZeolites, pages 94-101 and in the references cited therein. Preferably,a suitable pillared smectite clay comprises a multiplicity of cationsinterposed between the molecular layers of the clay and maintaining thespacing between the molecular layers in the range of from about 6angstroms to about 10 angstroms at a temperature of at least 300° C. inan air atmosphere for at least 2 hours.

Preferably, when the support comprises an aforesaid molecular sievematerial or an aforesaid pillared smectite or vermiculite clay materialor a combination thereof, the support also comprises an aforesaidamorphous refractory inorganic oxide. In such cases, the concentrationsof the amorphous inorganic oxide and of the molecular sieve materialand/or pillared smectite or vermiculite clay material are not critical.Preferably, the amorphous refractory inorganic oxide content is at leasthigh enough to be effective to give the support sufficient strength andintegrity so that the ultimate catalyst composition can be employed inthe method of the present invention without appreciable damage to thecatalyst. In such case, the total concentration of the molecular sievematerial and/or pillared smectite or vermiculite clay material in suchmixture is preferably from 5 to 90 weight percent, more preferably from20 to 60 weight percent, based on the weight of the support, whichsupport is made up of the amorphous refractory inorganic oxide and themolecular sieve material and/or the pillared smectite or vermiculiteclay material.

Preferably, when the support comprises a mixture of a molecular sieveand/or pillared smectite or vermiculite clay and an amorphous refractoryinorganic oxide, the support is in the form of a dispersion of themolecular sieve component and/or pillared smectite or vermiculite claycomponent in a matrix of the amorphous refractory inorganic oxide. Suchdispersions can be prepared by well-known techniques, such as blendingthe molecular sieve component and/or pillared smectite or vermiculiteclay component, preferably in finely-divided form, into a sol, hydrosolor hydrogel of the inorganic oxide, and then adding a gelling medium,such as ammonium hydroxide, and stirring to produce a gel. Alternately,the molecular sieve component and/or pillared smectite or vermiculiteclay component is blended into a slurry of the amorphous inorganicoxide. In either case, the resulting mixture can be dried, shaped, ifdesired, and then calcined to form the final support component. A lesspreferred, but still suitable, method for preparing a suitabledispersion of the molecular sieve component and/or pillared smectite orvermiculite clay component in the inorganic oxide is to dry-blendparticles of each, preferably in finely-divided form, and then toconduct any desired shaping operations, such as pelletizing orextrusion; the resulting mixture is then calcined.

The catalysts employed in the method of this invention can be preparedby impregnation of an aforesaid suitable support with at least oneprecursor of the cadmium component and optionally of the thoriumcomponent. Any convenient conventional impregnation technique can beemployed for this purpose. For example, when the support comprises anamorphous refractory inorganic oxide, a soluble cadmium compound and, ifa thorium component is to be present, a soluble thorium compound can beadded to a sol or gel of the amorphous refractory inorganic oxide. Thiscomposition is thoroughly blended, and the sol or gel mixture issubsequently co-gelled by the addition of a dilute ammonia solution. Theresulting co-gelled material is then dried and calcined. In anothermethod of preparation, the refractory inorganic oxide is gelled, dried,calcined, and cooled, and the resulting material is then impregnatedwith one or more solutions of a cadmium compound and, if a thoriumcomponent is to be present, of a thorium compound.

When the support comprises both an amorphous refractory inorganic oxideand a molecular sieve and/or a pillared smectite or vermiculite clay,numerous convenient impregnation techniques can also be employed. Forexample, finely-divided molecular sieve material and/or pillaredsmectite or vermiculite clay material can be stirred into a sol or gelof a refractory inorganic oxide, and at least one soluble compound ofcadmium--and optionally at least one soluble compound of thorium--isadded to the sol or gel, followed by co-gelling of the sol or gelmixture by the addition of dilute ammonia. The resulting co-gelledmaterial is then dried and calcined.

In another method of preparation, finely-divided molecular sievematerial and/or pillared smectite or vermiculite clay material are mixedinto a sol or gel of a refractory inorganic oxide; the sol or gelmixture is co-gelled by the addition of dilute ammonia and the resultinggel is subsequently dried, calcined, cooled, and then impregnated with asolution or solutions of at least one soluble compound of cadmium andoptionally of thorium. As an alternate method of preparation, a hydrogelof a refractory inorganic oxide is blended with finely-divided molecularsieve material and/or pillared smectite or vermiculite clay, and asolution or solutions of at least one soluble compound of cadmium and,optionally, of thorium is added to this blend, and the resulting mixtureis thoroughly blended. The blended mixture is then dried and calcined.

In still another method of preparation, the molecular sieve materialand/or pillared smectite or vermiculite clay material can be pulverizedinto a finely-divided state and then physically admixed with afinely-divided powder of the selected refractory inorganic oxidecomponent. After a thorough blending of the solid components, theresulting mixture can be co-pelleted, and impregnated with one or moresolutions of a cadmium compound and, optionally, of a thorium compound.

It is, of course, also suitable to impregnate only one of the amorphousrefractory inorganic oxide, the molecular sieve material or pillaredsmectite or vermiculite clay material in the mixture, or to impregnateeach of the aforesaid amorphous inorganic oxide, molecular sievematerial and/or pillared smectite or vermiculite clay materialseparately, and then to blend the inorganic oxide and molecular sievematerial and/or pillared smectite or vermiculite clay material. Thus, itis contemplated that, if the catalyst employed in the method of thisinvention comprises an amorphous refractory inorganic oxide and at leastone of a molecular sieve material and a pillared smectite or vermiculiteclay material, the cadmium component can be deposited on only one, onlytwo, or all of the components of the support. Similarly, in such cases,if a thoriun component is also present in the catalyst employed in themethod of this invention, the thorium component can be present with thecadmium component on the same component(s) of the support, or thecadmium component and thorium component can be on different componentsof the support.

It is preferred that, if the catalyst employed in the method of thisinvention comprises a support comprising a molecular sieve component ora pillared smectite or vermiculite clay component impregnated with thecadmium component and/or the thorium component, the impregnation of themolecular sieve component and pillared smectite or vermiculite claycomponent is conducted at a pH of at least about 2 in order to avoidsubstantial destruction of the crystallinity of the aforesaid supportcomponent. More preferably, the pH of the impregnating solution(s) insuch case is from about 2.5 to about 6 in order to ensure substantialretention of the crystallinity of the aforesaid support component. Ofcourse, the optimum pH range(s) of the impregnating solution(s) variessomewhat depending on the specific molecular sieve component andpillared smectite or vermiculite clay component employed in thepreparation of a given catalsyt.

In each of the above preparations involving a molecular sieve material,the molecular sieve material employed can be either in its unexchangedform or in its ion-exchanged form. Preferably, the molecular sievematerial is one which has previously been cation-exchanged. A suitablecation-exchange procedure comprises making a slurry of the molecularsieve material in a solution of a cation, such as ammonium ions, whichis to be exchanged with the alkali metal in the molecular sievematerial, stirring the slurry at a temperature of about 100° C. for atleast about 2 hours to about one week, filtering the slurry, washing thefiltered solid with distilled water, and drying and calcining the solid.

It is also suitable to incorporate the precursor of the cadmiumcomponent into the molecular sieve by cation exchange using aconvenient, conventional ion exchange procedure, such as the onedescribed generally hereinabove. Thus, the cadmium component can beincorporated into the molecular sieve support itself, in addition to orinstead of being deposited on the surface of the molecular sievesupport.

Suitable conditions for drying the above-described cadmium-impregnatedor cadmium-exchanged supports comprise a temperature in the range offrom about 90° C. to about 200° C. and a drying time of from about 0.5to about 30 hours. Suitable calcination conditions in such methodscomprise a temperature in the range of about 480° C. to about 760° C.and a calcination time of from about 2 to about 5 hours. Preferreddrying and calcination conditions are a temperature of about 120° C. forabout 1-2 hours and a temperature of about 538° C. for about 1-2 hours,respectively.

The general method of this invention comprises reacting an aromaticcompound, hydrogen and at least one of carbon monoxide and an alcoholcontaining from 1 to 6 carbon atoms, in the presence of an aforesaidcatalyst suitable for use in the method of this invention. Theconditions employed in the method of this invention include atemperature in the range of from about 300° C. to about 480° C. and apressure in the range of from about 5 to about 150 kilograms per squarecentimeter.

The aromatic compound employed in the method of this invention ispreferably an unsubstituted or alkylated benzene or naphthalene. Thealcohol preferably comprises methanol, ethanol, propanol or acombination thereof. The mole ratio of carbon monoxide or alcohol orboth-to-hydrogen is preferably in the range of from about 1:10 to about10:1, more preferably from about 4:1 to about 1:4; and the mole ratio ofcarbon monoxide or alcohol or both-to-aromatic compound is preferablyfrom about 10:1 to about 1:10, more preferably from about 2:1 to about1:10. Preferably, the space velocity of the aromatic compound is fromabout 0.02 to about 0.5 moles of the aromatic compound per gram ofcatalyst per hour. Preferably, the space velocity of the alcohol is fromabout 0.01 to about 0.1 mole of the alcohol per gram of catalyst perhour. It is also preferred that the reaction between the aromaticcompound, hydrogen and at least one of carbon monoxide and an alcoholcontaining from 1 to 6 carbon atoms is performed at a temperature in therange of from about 315° C. to about 450° C., at a pressure in the rangeof from about 30 to about 100 kilograms per square centimeter. Inaddition, the reaction between the aromatic compound, hydrogen and atleast one of carbon monoxide and an alcohol containing from 1 to 6carbon atoms is preferably performed in the presence of a catalystcomprising a support comprising cadmium-exchanged zeolite Y, rareearth-exchanged zeolite Y, ultrastable zeolite Y, a pillared smectite orvermiculite clay, silica-alumina, crystalline borosilicate molecularsieve, or ZSM-5. More preferably, the catalyst support comprisescrystalline borosilicate molecular sieve or ZSM-5, and in such cases,the feed is preferably benzene or toluene, and at least one of p-xyleneand pseudocumene is produced. Preferably carbon monoxide is a reactant.

The present invention will be more clearly understood from the followingspecific examples.

EXAMPLE 1

A solution containing 3 grams of Cd(NO₃)₂.4H₂ O in 14 milliliters ofwater was combined and blended for 1 hour with 23.75 grams of gammaalumina (from Continental Oil Company and designated Catapal) having apore volume of 0.65 cubic centimeter per gram, a surface area of 200square meters per gram, an average pore diameter of 130 angstroms, and aparticle size of 0.16 centimeter. The blend was then dried at 120° C.for 1 hour and calcined at 540° C. in air for 1 hour. The resultingcatalyst contained 5 weight percent of cadmium oxide, based on theweight of the catalyst.

EXAMPLE 2

The procedure of Example 1 was repeated except that a solutioncontaining 3 grams of Cd(NO₃)₂.4H₂ O and 7.84 grams of Th(NO₃)₄.4H₂ O in9 milliliters of water was combined and blended with the alumina. Theresulting catalyst contained 5 weight percent of cadmium oxide and 15weight percent of thorium oxide, based on the weight of the catalyst.

EXAMPLE 3

35.4 grams of Th(NO₃)₄.4H₂ O was dissolved in water and blended with555.7 grams of an alumina sol containing about 9 weight percent ofalumina. 25 milliliters of an aqueous solution containing about 28weight percent of ammonium hydroxide was added to the resulting blend togel the sol. The resulting gel was dried at 120° C. overnight and thencalcined at 540° C. in air for 4 hours. The resulting composite materialcontained 25 weight percent of thorium oxide. A solution containing 6grams of Cd(NO₃)₂.4H₂ O in 10 milliliters of water was then blended with18 grams of the composite and the procedure of Example 1 was followed.The resulting catalyst contained 10 weight percent of cadmium oxide and22.5 weight percent of thorium oxide, based on the weight of thecatalyst.

EXAMPLE 4

691 grams of an alumina sol containing about 10 weight percent ofalumina was blended with 3000 grams of a silica-alumina sol containingabout 5.24 weight percent of silica-alumina of which about 72 weightpercent was silica and about 28 weight percent was alumina. 400milliliters of an aqueous solution containing about 50 weight percent ofammonium hydroxide was blended with the aforesaid blend until a pastyconsistency was achieved.

This procedure was repeated twice so that 3 batches of the paste werecollected. The 3 batches were then combined, and 1 liter of theaforesaid aqueous ammonium hydroxide solution was added to the resultingcombination. After standing for 24 hours, the resulting mixture wasdried in air at 120° C. for several days, ground and sieved to pass a100 mesh sieve (U.S. Series). The resulting solid was mulled with waterand a small amount of PHF alumina, and was then extruded to a diameterof 0.16 centimeter. The extrudate was dried overnight in air at 120° C.and then calcined in air at 538° C. for 4 hours. The resulting materialcontained 50 weight percent of alumina and 50 weight percent of silica,and had a pore volume of 0.48 cubic centimeter per gram, a surface areaof 227 square meters per gram and an average pore diameter of 110 Å.

The procedure of Example 1 was then repeated except that a solutioncontaining 10.82 grams of Cd(NO₃)₂.4H₂ O in 41 milliliters of water wasblended with 45.5 grams of the resulting silica-alumina containing 50weight percent of silica and 50 weight percent of alumina. The resultingcatalyst contained 9 weight percent of cadmium oxide, based on theweight of the catalyst.

EXAMPLE 5

The procedure of Example 4 was repeated, except that a solutioncontaining 5.4 grams of Cd(NO₃)₂.4H₂ O and 7.84 grams of Th(NO₃)₂.4H₂ Owas blended with 19 grams of the type of the silica-alumina compositecontaining 50 weight percent of silica and 50 weight percent of aluminaand used in Example 4. The resulting catalyst contained 9 weight percentof cadmium oxide and 15 weight percent of thorium oxide, based on theweight of the catalyst.

EXAMPLE 6

The procedure of Example 4 was repeated, except that a solutioncontaining 3 grams of Cd(NO₃)₂.4H₂ O and 6.27 grams of Th(NO₃)₂.4H₂ Owas blended with 16 grams of the type of the silica-alumina compositecontaining 50 weight percent of silica and 50 weight percent of aluminaand used in Example 4. The resulting catalyst contained 5 weight percentof cadmium oxide and 15 weight percent of thorium oxide, based on theweight of the catalyst.

EXAMPLE7

3000 grams of zeolite Y in the sodium form (from Union CarbideCorporation and designated LZ-Y52) was slurried in 8 liters of water,and 4000 grams of a solution of a commercially available mixture of rareearth chlorides was added to the slurry. The resulting slurry wasstirred and heated at reflux for 1 hour. The solids were allowed tosettle overnight and the supernatant liquid was siphoned off. Theresulting solids were exchanged a second time with 4 kilograms of themixture of rare earth chlorides in 2 liters of water, and the aforesaidstirring, refluxing, settling and siphoning steps were repeated. Theresulting solids were exchanged a third time with 4 kilograms of themixture of rare earth chlorides in 6 liters of water, and the aforesaidstirring, refluxing, settling and siphoning steps were repeated. Theresulting solids were washed each of 4 times with 6 liters of water,dried overnight at 120° C. and calcined for 4 hours at about 780° C.

The aforesaid triple exchange was repeated, except using instead in eachexchange solution 2000 grams of the mixture of rare earth chlorides andadditionally in the third exchange solution 400 grams of ammoniumnitrate. The stirring, refluxing, settling, siphoning, washing anddrying steps were as described for the first triple exchange.

The aforesaid triple exchange was repeated a second time, using the samesteps and conditions employed in the aforesaid second triple exchange.

The final rare earth-exchanged zeolite Y demonstrated 92 percentcrystallinity and contained 0.241 weight percent of sodium, 2.4 weightpercent of lanthanum, 8.6 weight percent of cerium, 2.9 weight percentof neodymium, 0.20 weight percent of thorium, 1.1 weight percent ofyttrium, 6.6 weight percent of aluminum and 24.8 weight percent ofsilicon.

120.0 grams of the resulting rare earth-exchanged zeolite Y was groundto pass a 100 mesh sieve (U.S. Series) and mixed with approximately 400milliliters of water. The resulting mixture was blended with 2800 gramsof an alumina sol containing about 10 weight percent of alumina. 300milliliters of an aqueous solution of ammonium hydroxide containing 50weight percent of ammonium hydroxide was added rapidly to the resultingblend, with stirring, to gel the mixture of the rare earth-exchangedzeolite Y and alumina. The gelled material was dried at 120° C. for 40hours. The dried material was then ground to pass a 100 mesh sieve (U.S.Series), mulled with water and extruded to a diameter of 0.2 centimeter.The extrudate was dried at 120° C. in air for 6 hours and then calcinedat 540° C. in air for 6 hours. The resulting composition contained 30weight percent of rare earth-exchanged zeolite Y and 70 weight percentof alumina.

EXAMPLE 8

A solution containing 1.91 grams of Cd(NO₃)₂.4H₂ O in 6.5 milliliters ofwater was combined and blended for 1 hour with 15.1 grams of the finalrare earth-exchanged zeolite Y produced in Example 7. The blend was thendried at 120° C. for 1 hour and calcined at 540° C. in air for 1 hour.The resulting catalyst contained 5 weight percent of cadmium oxide,based on the weight of the catalyst.

EXAMPLE 9

A solution containing 3 grams of Cd(NO₃)₂.4H₂ O and 7.84 grams ofTh(NO₃)₄.4H₂ O in 8 milliliters of water was combined and blended for 1hour with 20 grams of the final rare earth-exchanged zeolite Y producedin Example 7. The blend was then dried at 120° C. for 1 hour andcalcined at 540° C. in air for 1 hour. The resulting catalyst contained5 weight percent of cadmium oxide and 15 weight percent of thoriumoxide, based on the weight of the catalyst.

EXAMPLE 10

A solution containing 12 grams of Cd(NO₃)₂.4H₂ O in 7 milliliters ofwater was combined and blended for 1 hour with 20 grams of the finalrare earth-exchanged zeolite Y produced in Example 7. The blend was thendried at 120° C. for 1 hour and calcined at 540° C. in air for 1 hour.The resulting catalyst contained 20 weight percent of cadmium oxide,based on the weight of the catalyst.

EXAMPLE 11

25 grams of rare earth-exchanged zeolite Y prepared as in Example 7 wasground to pass a 100 mesh sieve (U.S. Series) and suspended in water.The resulting suspension was blended with 275 grams of an alumina solcontaining about 9 weight percent of alumina. 13 milliliters of anaqueous solution containing 28 weight percent of ammonium hydroxide wasthen added rapidly, with stirring, to the resulting blend to gel themixture of the rare earth-exchanged zeolite Y and alumina. The resultinggelled material was dried overnight at 120° C. and calcined at 540° C.in air for 1 hour. The resulting composition contained 50 weight percentof rare earth-exchanged zeolite Y and 50 weight percent of alumina.

A solution containing 13.4 grams of Cd(NO₃)₂.4H₂ O and 17.5 grams ofTh(NO₃)₄.4H₂ O in 16 milliliters of water was combined and blended for 1hour with 44.7 grams of the aforesaid composition containing 50 weightpercent of rare earth-exchanged zeolite Y and 50 weight percent ofalumina. The blend was then dried at 120° C. for several hours andcalcined at 540° C. in air for 4 hours. The resulting catalyst contained5 weight percent of cadmium oxide and 15 weight percent of thoriumoxide, based on the weight of the catalyst.

EXAMPLE 12

90 grams of H-Zeolon (Zeolon 200 from the Norton Company) was ground topass a 100 mesh sieve (U.S. Series), and the resulting particles wereslurried with distilled water. The resulting slurry was blended with3600 grams of an alumina sol containing about 10 weight percent ofalumina. 215 milliliters of an aqueous solution containing about 50weight percent of ammonium hydroxide was then added to gel the mixtureof H-Zeolon and alumina. The resulting gel was dried over a period ofseveral days at 120° C. in air. The dried particles were ground to passa 100 mesh sieve (U.S. Series), mulled with water and extruded to adiameter of 0.2 centimeter. The extrudate was dried at 120° C. for 2hours in air and calcined at 540° C. for 7 hours in air. The resultingcomposition contained 20 weight percent of H-Zeolon and 80 weightpercent of alumina.

A solution containing 3 grams of Cd(NO₃)₂.4H₂ O and 7.84 grams ofTh(NO₃)₄.4H₂ O in 8 milliliters of water was combined and blended with20 grams of the aforesaid composition containing 20 weight percent ofH-Zeolon in alumina. The blend was then dried at 120° C. for 1 hour andcalcined at 540° C. in air for 1 hour. The resulting catalyst contained5 weight percent of cadmium oxide and 15 weight percent of thoriumoxide, based on the weight of the catalyst.

EXAMPLE 13

180 grams of crystalline borosilicate (obtained from Amoco ChemicalsCorporation and designated HAMS-1B) was suspended in sufficient water toform a sauce-like consistency and combined and blended with 3600 gramsof an alumina sol containing about 10 weight percent of alumina. 400milliliters of an aqueous solution containing about 50 weight percent ofammonium hydroxide was added to the blend to gel the mixture ofcrystalline borosilicate and alumina. The resulting gel was dried at120° C. in air overnight. The dried particles were ground to pass a 100mesh sieve (U.S. Series), mulled with water, extruded to a diameter of0.32 centimeter, dried at 120° C. overnight and calcined at 540° C. inair overnight. The resulting composition contained 40 weight percent ofcrystalline borosilicate HAMS-1B and 60 weight percent of alumina.

A solution containing 3 grams of Cd(NO₃)₂.4H₂ O and 7.84 grams ofTh(NO₃)₄.4H₂ O in 8 milliliters of water was combined and blended for 1hour with 20 grams of the aforesaid composition containing 40 weightpercent of HAMS-1B. The blend was then dried at 120° C. for 1 hour andcalcined at 540° C. in air for 1 hour. The resulting catalyst contained5 weight percent of cadmium oxide and 15 weight percent of thoriumoxide, based on the weight of the catalyst.

EXAMPLE 14

The procedure of Example 13 was repeated except that a solutioncontaining 3 grams of Cd(NO₃)₂.4H₂ O in 8 grams of water was combinedand blended with 19 grams of the composition containing 40 weightpercent of crystalline borosilicate HAMS-1B and 60 weight percent ofalumina. The blend was then dried at 120° C. for 1 hour and calcined at540° C. in air for 1 hour. The resulting catalyst contained 5 weightpercent of cadmium oxide, based on the weight of the catalyst.

EXAMPLE 15

ZSM-5 having a mole ratio for silica-to-alumina of 30:1 was prepared bydissolving 208 grams of tetrapropylammonium bromide and 42 grams ofsodium aluminate in 400 milliliters of an aqueous solution containing37.2 grams of sodium hydroxide. Then 1077 grams of Ludox (a silica sol)and sufficient water to bring the total solution volume to 18 literswere blended with the aforesaid aqueous solution. The blend was thenheated at about 150° C. for 5 days in an autoclave. Thereafter the solidwas washed with hot water 3 times, dried overnight at about 120° C. andthen calcined at about 540° C.

350 grams of 30:1 ZSM-5 was ground to pass a 100 mesh sieve (U.S.Series) and then suspended in water. The resulting suspension wascombined with 2265.4 grams of an alumina sol containing about 10 weightpercent of alumina. 400 milliliters of an aqueous solution containingabout 14 weight percent of ammonium hydroxide was added to the resultingmixture to form a gel. The resulting gel was dried at 120° C. in air.The dried material was then ground to pass a 100 mesh sieve (U.S.Series) and extruded to a diameter of 0.32 centimeter. The extrudate wasdried at 120° C. and then calcined at 540° C. for 20 hours. Theresulting composition contained 60 weight percent of ZSM-5 and 40 weightpercent of alumina.

A solution containing 3 grams of Cd(NO₃)₂.4H₂ O and 7.84 grams ofTh(NO₃)₄.4H₂ O in 8 milliliters of water was combined and blended for 1hour with 20 grams of the aforesaid composition containing 60 weightpercent of ZSM-5 and 40 weight percent of alumina. The blend was thendried at 120° C. for 1 hour and calcined at 540° C. in air for 1 hour.The resulting catalyst contained 5 weight percent of cadmium oxide and15 weight percent of thorium oxide, based on the weight of the catalyst.

EXAMPLE 16

A solution containing 150 grams of Cd(NO₃)₂.4H₂ O in 800 milliliters ofwater was added to approximately 100 grams of zeolite Y (LZ-Y52 fromUnion Carbide) having exchangeable sodium ions. This mixture was stirredand heated for 2 hours, and then filtered and washed, to therebyexchange cadmium ions for some of the exchangeable sodium ions in thezeolite Y. A second solution containing 150 grams of Cd(NO₃)₂.4H₂ O wasadded to the resulting cadmium-exchanged zeolite Y, and the resultingmixture was again stirred and heated for 2 hours. The resulting mixturewas allowed to settle overnight and then filtered. The separated solidzeolite Y containing cadmium ions exchanged for some of the sodium ionsoriginally present, was washed with water.

30 grams of this composition was suspended in water, and the resultingsuspension was combined with 768.4 grams of an alumina sol containingabout 10 weight percent of alumina. 35 milliliters of an aqueoussolution containing about 28 weight percent of ammonium hydroxide wasadded to gel the mixture. The resulting gel was dried overnight at 120°C. and then calcined at 540° C. for 4 hours. The resulting catalystcontained 30 weight percent of the cadium-exchanged zeolite Y and 70weight percent of alumina. The cadmium, calculated as cadmium oxide,constituted 5.6 weight percent of the catalyst.

EXAMPLE 17

A solution containing 100 grams of Cd(NO₃)₂.4H₂ O in 900 milliliters ofwater was combined with 100 grams of zeolite omega-5 (obtained fromUnion Carbide and designated ELZ-Ω-5) having exchangeable sodium ions.The resulting mixture was heated for 2 hours at 38° C., with stirring,and then filtered and washed with water, to thereby exchange cadmiumions for some of the exchangeable ions in the zeolite omega-5. A secondsolution containing 100 grams of Cd(NO₃)₂.4H₂ O in 900 milliliters ofwater was added to the resulting cadmium-exchanged zeolite omega-5, andthe resulting mixture was again stirred, heated, allowed to settle andfiltered. The final twice-cadmium-exchanged zeolite omega-5 was driedovernight at 120° C.

48.1 grams of this composition was ground to pass a 100 mesh sieve (U.S.Series) and suspended in water. This suspension was mixed with 351.85grams of an alumina sol containing about 10 weight percent of alumina,and 16 milliliters of an aqueous solution containing about 28 weightpercent of ammonium hydroxide was added to gel the mixture of zeoliteomega-5 and alumina. The resulting gel was dried at 120° C. overnightand then calcined in air at 540° C. for 6 hours. The resulting catalystcontained 60 weight percent of the cadmium-exchanged zeolite omega-5 and40 weight percent of alumina.

EXAMPLE 18

100 grams of zeolite L (obtained from Union Carbide and designatedELZ-L) was combined with 900 milliliters of water, and potassiumhydroxide was added to the resulting mixture to adjust the pH toapproximately 11. The mixture was heated at 38° C. for 1 hour, filteredand washed. The recovered solid was combined with a solution containing100 grams of Cd(NO₃)₂.4H₂ O in 800 milliliters of water, and theresulting mixture was heated and stirred for 2 hours, after which timeit was allowed to cool and settle overnight. The resultingonce-cadmium-exchanged zeolite L was separated by filtration and washedwith water, and then re-suspended in 800 milliliters of water. To thissuspension 100 grams of Cd(NO₃)₂.4H₂ O was added, and the resultingsuspension was heated at 38° C. and stirred for 2 hours. The mixture wasthen allowed to cool and settle overnight. The resultingtwice-cadmium-exchanged zeolite L was separated by filtration, washedwith water and then dried overnight at 120° C.

79.87 grams of this composition was ground to pass a 100 mesh sieve(U.S. Series) and suspended in water. The suspension was then combinedwith 584.5 grams of an alumina sol containing about 10 weight percent ofalumina, and 27 milliliters of an aqueous solution containing about 28weight percent of ammonium hydroxide was added to gel the mixture ofzeolite L and alumina. The resulting gel was dried at 120° C. overnightand then calcined at 540° C. for 6 hours. The resulting compositioncontained 60 weight percent of the cadmium-exchanged zeolite L and 40weight percent of alumina.

EXAMPLE 19

A suspension of 400 grams of a bentonite, 90 weight percent of which ismontmorillonite (supplied by American Colloid Company and designatedVolclay 325), in 227 cubic centimeters of water was mixed with 304 gramsof a 50 weight percent solution of Reheis alumina Chlorhydrol, and thepH of the resulting suspension was adjusted to 4 with ammoniumhydroxide. The suspension was heated at 72° C. for 1 hour and thenfiltered, and the resulting separated solid was washed with water, driedat 100° C. and calcined at 500° C. for 2 hours. The resultingalumina-expanded smectite clay had a d-spacing of 16.6 angstroms asmeasured by X-ray diffraction. The spacing between the molecular layersof the montmorillonite was between 6 and 10 angstroms and was stable ata temperature of at least 300° C. in an air atmosphere for at least 2hours.

30.27 grams of this composition was combined with 221.5 grams of analumina sol containing about 9 weight percent of alumina, and 10 gramsof an aqueous solution containing about 28 weight percent of ammoniumhydroxide was added to gel the resulting mixture. The resulting gel wasdried at 120° C. and calcined at 540° C. for 6 hours. The resultingcomposition contained 60 weight percent of the alumina-expanded smectiteclay and 40 weight percent of alumina.

A solution containing 2.4 grams of Cd(NO₃)₂.4H₂ O in 8 milliliters ofwater was combined and blended with 19 grams of the aforesaidcomposition containing 60 weight percent of the alumina-expandedsmectite clay and 40 weight percent of alumina. The blend was then driedat 120° C. and calcined at 540° C. for 4 hours. The resulting catalystcontained 5 weight percent of cadmium oxide, based on the weight of thecatalyst.

EXAMPLE 20

The procedure of Example 19 was repeated except that a solutioncontaining 5.41 grams of Cd(NO₃)₂.4H₂ O in 9 grams of water was combinedand blended with 22.75 grams of the composition containing 60 weightpercent of the alumina-expanded smectite clay and 40 weight percent ofalumina. The blend was then dried at 120° C. and calcined at 540° C. for4 hours. The resulting catalyst contained 9 weight percent of cadmiumoxide, based on the weight of the catalyst.

EXAMPLE 21

90 grams of ultrastable zeolite Y crystalline aluminosilicate wasslurried in water, and the slurry was combined and blended with 3600grams of an alumina sol containing about 10 weight percent of alumina.250 grams of an aqueous solution containing about 28 weight percent ofammonium hydroxide was added to gel the resulting mixture. The resultinggel was dried at 120° C. and then ground to pass a 100 mesh sieve (U.S.Series). The ground material was next mulled with water and extruded toa 0.16 centimeter diameter. The extrudate was dried overnight at 120° C.and calcined at 540° C. for 7 hours. The resulting composition contained30 weight percent of ultrastable zeolite Y and 70 weight percent ofalumina.

A solution containing 3 grams of Cd(NO₃)₂.4H₂ O and 7.84 grams ofTh(NO₃)₂.4H₂ O in 8 grams of water was blended with the aforesaidcomposition containing ultrastable zeolite Y and alumina. The resultingmixture was dried at 120° C. and then calcined at 540° C. for 1 hour.The resulting catalyst contained 5 weight percent of cadmium oxide and15 weight percent of thorium oxide, based on the weight of the catalyst.

EXAMPLE 22

360 grams of ultrastable zeolite Y crystalline aluminosilicate wasslurried in water, and the slurry was combined and blended with 3600grams of an alumina sol containing about 10 weight percent of alumina.400 grams of an aqueous solution containing about 28 weight percent ofammonium hydroxide was added to gel the resulting mixture. The resultinggel was dried at 120° C. and then ground to pass a 100 mesh sieve (U.S.Series). The ground material was next mulled with water and extruded toa 0.16 centimeter diameter. The extrudate was dried overnight at 120° C.and calcined at 540° C. for 3 hours. The resulting composition contained50 weight percent of ultrastable zeolite Y and 50 weight percent ofalumina.

A solution containing 2.4 grams of Cd(NO₃)₂.4H₂ O in 8 grams of waterwas blended with the aforesaid composition containing ultrastablezeolite Y and alumina. The resulting mixture was dried at 120° C. andthen calcined at 540° C. for 4 hours. The resulting catalyst contained 5weight percent of cadmium oxide, based on the weight of the catalyst.

EXAMPLES 23-32

Examples 23-32 were performed using a 300-cubic centimeter, back-mixedreactor in which the flow into the reactor of each gaseous and liquidreactant employed was controlled individually. To start a run in each ofExamples 23-32, 10 grams of the particular catalyst used was loaded intothe reactor, and the reactor was closed. The pressure of the reactor wasthen raised to the desired level by introducing the gaseous reactant(s)employed. The temperature of the reactor was then raised to the desiredlevel, at which point any liquid reactant(s) employed was thenintroduced into the reactor where it contacted the catalyst and gaseousreactant(s). Products and unreacted reactants passed continuously out ofthe reactor.

The catalyst, temperature, pressure and feed rates of each reactantemployed in Examples 23-32 are presented in Tables 1-3. The feed rate ofeach liquid reactant is presented in Tables 1-3 in terms of its liquidhourly space velocity--that is, the feed rate of the liquid in cubiccentimeters per hour divided by the number (10) of grams of catalyst inthe reactor. The combined feed rate of the gaseous reactant(s) ispresented in Tables 1-3 in terms of the gas weight hourly spacevelocity--that is, the combined gaseous feed rate in cubic centimetersper hour divided by weight of catalyst in the reactor. Both carbonmonoxide and hydrogen were employed in each example except Examples 27and 31 and were introduced into the reactor at a mole ratio of carbonmonoxide-to-hydrogen of 1:2. In Examples 27 and 31, hydrogen was theonly gas employed. Benzene is the aromatic liquid feed in Examples 23,24 and 29, and toluene is the aromatic liquid feed in Examples 25, 26,27, 28, 30, 31 and 32. Methanol is also a feed in Examples 27 and 31.

The compositions of the organic products for each of Examples 23-32 arealso indicated in Tables 1-3. The product fraction reported asm/p-xylene in Tables 1 and 3 is substantially all p-xylene. In each ofthe tables, T indicates trace amounts.

                  TABLE 1    ______________________________________    Example No.     23      24      25    26    ______________________________________    Catalyst from   14      14      13    13    Example No.    Temperature (°C.)                    399     421     399   405    Pressure (atm.) 34      34      34    68    Gas feed rate   1550    1550    850   1550    (cc./hr./gm.)   1550    1550    850   1550    Liquid feed rate                    1.0.sup.1                            1.0.sup.1                                    1.0.sup.2                                          1.0.sup.2    (cc./hr./gm.)    Aromatic        24      29      25    60    conversion (%)    Product Composition (Wt. %)    C.sub.1 -C.sub.6                    5       5       6     3    Benzene         --      --      12    2    Toluene         65      47      --    --    Ethylbenzene    2       2       --    --    m/p-xylene      14      24      45    30    o-xylene        --      --      16    12    1,3,5-trimethylbenzene                    --      --      --    2    pseudocumene    3       9       8     23    1,2,3-trimethylbenzene                    1       --      --    1    tetramethylbenzene                    3       1       2     16    Other aromatics --      14      11    11    ______________________________________     Footnotes     .sup.1 Benzene     .sup.2 Toluene

                  TABLE 2    ______________________________________    Example No.        27       28    ______________________________________    Catalyst from      22       22    Example No.    Temperature (°C.)                       399      400    Pressure (atm.)    34       34    Gas feed rate      1700     1850    (cc./hr./gm.)    Liquid feed rate   1.sup.1 + 1.sup.2                                 1.sup.1    (cc./hr./gm.)    Aromatic           40       52    conversion (%)    Liquid Product Composition (Wt. %).sup.3    Benzene             9        9    Xylenes            56       68    Trimethylbenzenes and                       35       23    Tetramethylbenzenes    ______________________________________     Footnotes     .sup.1 Toluene     .sup.2 Methanol     .sup.3 Wt. % of toluene converted

                  TABLE 3    ______________________________________    Example No.    29     30       31     32    ______________________________________    Catalyst from   8      8        22     4    Example No.    Temperature (°C.)                   399    399      399    393    Pressure (atm.)                    34     34       34     68    Gas feed rate  850    850      1400   1800    (cc./hr./gm.)    Liquid feed rate                    1.sup.1                           1.sup.2 1.sup.2 + 1.sup.3                                           1.sup.2    (cc./hr./gm.)    Aromatic       37.41  44.8     69.6.sup.4                                          19.7    conversion (%)    Product Composition (Wt. %)    C.sub.1 -C.sub.2                   --     1.3      --     11.3    C.sub.3        --     3.0      --     --    i-C.sub.4      --     3.6      --      7.9    n-C.sub.4      --     0.3      --     --    Other C.sub.6 -                   6.4    3.4       5.0   --    Cyclohexane    1.4    2.3      --     --    Benzene        --     8.8      --     0    Toluene        52.2   --       --     --    m/p-xylene     8.4    33.2     21.6   28.4    o-xylene       9.7    8.5       3.9   19.5    Trimethylbenzenes                   --     12.2     20.6    7.6    Other C.sub.6 +, includ-                   21.9   23.4     22.8   16.2    ing aromatics    Tetramethylbenzenes                   --     --       14.3   --    Pentamethylbenzenes                   --     --        7.3   --    Hexamethylbenzenes                   --     --        4.7   --    ______________________________________     Footnotes     .sup.1 Benzene     .sup.2 Toluene     .sup.3 Methanol     .sup.4 Approximately 100% methanol conversion

Examples 23-32 involve the reaction between an aromatic compound,hydrogen and at least one of carbon monoxide and an alcohol containingfrom 1 to 6 carbon atoms. In all cases, products that are methylatedderivatives--other than disproportionation products--of the aromaticcomponent of the feed were formed. Examples 23-32 illustrate thatincreases in reaction temperature or pressure afford increasedconversion of the aromatic feed component, and increased overall yieldsof polymethylated products, such as pseudocumene, tetramethylbenzenesand other aromatics. However, increasing the pressure with the toluenefeed resulted in decreases in the percentage of p-xylene in the productsand in increases in the proportion of heavier aromatics. Comparison ofthe results of Examples 23 and 29 with those of Examples 25 and 30,respectively, illustrates that the use of toluene instead of benzene inthe feed results in greater aromatic conversion and a greater totalyield of the more highly methylated products. Comparison of the resultsof Examples 27 and 28 indicates that replacement of methanol by carbonmonoxide in the feed results in a substantial increase in the degree ofaromatic conversion, but a relatively lower total yield oftrimethylbenzenes and tetramethylbenzenes. In the absence of a cadmiumcomponent in the catalyst, the aforesaid methylation reactions do notoccur when synthesis gas is used.

In runs corresponding to Examples 29 and 30 in every respect except thatcarbon monoxide was not employed, no reaction occurred when benzene wasthe aromatic feed, and considerable hydrocracking and formation of lightaliphatic compounds and benzene occurred when toluene was the feed. Runscorresponding to Example 31 in every respect except that differentamounts of methanol were employed demonstrated that the yield anddistribution of polymethylated aromatics can be controlled by usinggreater or lesser amounts of methanol.

From the above description, it is apparent that the objects of thepresent invention have been achieved. While only certain embodimentshave been set forth, alternative embodiments and various modificationswill be apparent from the above description to those skilled in the art.These and other alternatives are considered equivalents and within thespirit and scope of the present invention.

Having described the invention, what is claimed is:
 1. A method for reacting an aromatic compound, hydrogen and at least one of carbon monoxide and an alcohol containing from 1 to 6 carbon atoms, at a temperature in the range of from about 300° C. to about 480° C., at a pressure in the range of from about 5 to about 150 kilograms per square centimeter, and in the presence of a catalyst composition comprising a cadmium component and a support material having acidic properties, wherein the cadmium component is in the form of the elemental metal, its oxide or salt or a combination thereof, and wherein the cadmium component is present at a concentration level in the range of from about 0.1 to about 20 weight percent, calculated as cadmium oxide and based on the weight of the catalyst.
 2. The method of claim 1 wherein the mole ratio of carbon monoxide or alcohol or both-to-hydrogen is in the range of from about 1:10 to about 10:1, and the mole ratio of carbon monoxide or alcohol or both-to-aromatic compound is in the range of from about 10:1 to about 1:10.
 3. The method of claim 1 wherein the aromatic compound is an unsubstituted or alkylated benzene or naphthalene.
 4. The method of claim 1 wherein the alcohol comprises methanol, ethanol, propanol or a combination thereof.
 5. The method of claim 1 wherein the reaction is performed at a temperature in the range of from about 315° C. to about 450° C., a pressure in the range of from about 30 to about 100 kilograms per square centimeter, a mole ratio of carbon monoxide or alcohol or both-to-hydrogen of in the range of from about 4:1 to about 1:4 and a mole ratio of carbon monoxide or alcohol or both-to-aromatic compound of in the range of from about 2:1 to about 1:10.
 6. The method of claim 1 wherein the space velocity of the aromatic compound is in the range of from about 0.02 to about 0.5 moles of the aromatic compound per gram of catalyst per hour.
 7. The method of claim 1 wherein the space velocity of the alcohol that is present is from about 0.01 to about 0.1 moles of the alcohol per gram of catalyst per hour.
 8. The method of claim 1 wherein the cadmium component is in the form of cadmium oxide.
 9. The method of claim 1 wherein the cadmium component is present at a concentration level in the range of from about 1 to about 10 weight percent, calculated as cadmium oxide and based on the weight of the catalyst.
 10. The method of claim 2 wherein the support comprises a refractory inorganic oxide, a molecular sieve, a pillared smectite or vermiculite clay or a combination thereof.
 11. The method of claim 10 wherein the refractory inorganic oxide comprises alumina, zirconia, titania, an oxide of the lanthanide series, an oxide of the actinide series, a combination thereof, or a combination thereof with silica or magnesia.
 12. The method of claim 10 wherein the molecular sieve comprises a crystalline aluminosilicate or crystalline borosilicate, or mixture thereof, in the unexchanged or cation-exchanged form.
 13. The method of claim 12 wherein the crystalline aluminosilicate comprises chabazite, mordenite, erionite, clinoptilolite, zeolite A, zeolite L, zeolite X, zeolite Y, ultrastable zeolite Y, zeolite omega, ZSM-5, ZSM-11, ZSM-12, ZSM-35, ZSM-38 or ZSM-48.
 14. The method of claim 13 wherein the crystalline aluminosilicate is in the hydrogen- or rare earth-exchanged form.
 15. The method of claim 12 wherein the crystalline borosilicate molecular sieve comprises a molecular sieve material having the following composition in terms of mole ratios of oxides:

    0.9±0.2M.sub.2/n O:B.sub.2 O.sub.3 :ySiO.sub.2 :zH.sub.2 O

wherein M is at least one cation having a valence of n, y is between 4 and about 600, and z is between 0 and about 160, and providing an X-ray diffraction pattern comprising the following X-ray diffraction lines and assigned strengths

    ______________________________________     ˜d (Å)                   Assigned Strength     ______________________________________     11.2 ± 0.2 W- VS     10.0 ± 0.2 W- MS     5.97 ± 0.07                   W- M     3.82 ± 0.05                   VS     3.70 ± 0.05                   MS     3.62 ± 0.05                   M- MS     2.97 ± 0.02                   W- M     1.99 ± 0.02                   VW- M.     ______________________________________


16. The method of claim 10 wherein the pillared smectite or vermiculite clay comprises a multiplicity of cations interposed between the molecular layers of the clay and maintaining the spacing between the molecular layers in the range of from about 6 angstroms to about 10 angstroms at a temperature of at least 300° C. in an air atmosphere for at least 2 hours.
 17. The method of claim 10 wherein the support comprises from about 20 to about 95 weight percent of an aforesaid refractory inorganic oxide and from about 5 to about 80 weight percent of an aforesaid molecular sieve or pillared smectite clay.
 18. The method of claim 10 wherein the support comprises cadmium-exchanged zeolite Y, rare earth-exchanged zeolite Y, ultrastable zeolite Y, a pillared smectite or vermiculite clay, silica-alumina, crystalline borosilicate molecular sieve or ZSM-5.
 19. The method of claim 18 wherein the support comprises crystalline borosilicate molecular sieve or ZSM-5.
 20. The method of claim 19 wherein the aromatic compound is benzene or toluene and at least one of p-xylene and pseudocumene is produced.
 21. The method of claim 1 wherein the catalyst comprises additionally a thorium component on the support wherein the thorium component is in the form of elemental thorium, its oxide or salt or a combination thereof and is present at a concentration in the range of from about 1 to about 25 weight percent, calculated as thorium oxide and based on the weight of the catalyst.
 22. The method of claim 21 wherein the thorium component is in the form of thorium oxide. 